Unique PDC microstructure and the method of making it

Patent metadata

Field	Value
Publication number	US-12104111-B2
Application number	US-202217654721-A
Country	US
Kind code	B2
Filing date	Mar 14, 2022
Priority date	Mar 14, 2022
Publication date	Oct 1, 2024
Grant date	Oct 1, 2024

Abstract

A superabrasive compact and a method of making the superabrasive compact are disclosed. A superabrasive compact may comprise a diamond table and a substrate. The diamond table may be attached to the substrate. The diamond table may include bonded diamond grains defining interstitial channels. The interstitial channels may be filled with non-catalytic binder materials in some regions. The interstitial channels in some other regions may be filled with a catalytic materials from the substrate.

First claim

We claim:

1. A method of making a superabrasive compact, comprising:
mixing a non-catalytic binder with a plurality of diamond particles, wherein the non-catalytic binder is at least one of Titanium, MqCO 3 , CaCO 3 , Boron, Tantalum, Cr 2 AIC, or Niobium;
subjecting the non-catalytic binder and the plurality of diamond particles to first conditions of temperature and pressure suitable for producing an agglomerate granule;
mixing the agglomerate granule with a third plurality diamond particles; and
positioning the resulting mixture proximate to a substrate, wherein the substrate has hard metal carbides and a binder having carbon at least partially dissolved therein;
subjecting the resulting mixture and the hard metal carbides to second conditions of temperature and pressure suitable to produce the superabrasive compact.

2. The method of claim 1 , wherein the plurality of diamond particles comprise a first plurality of diamond particles with a size ranging from about 1 to about 10 μm.

3. The method of claim 2 , wherein the plurality of diamond particles comprise a second plurality of diamond particles with a size ranging from about 10 nm to about 5 μm.

4. The method of claim 3 , wherein the other plurality of diamond particles comprise a third plurality of diamond particles with a size ranging from about 10 μm to about 100 μm.

5. The method of claim 4 , wherein the agglomerate granule has a size of about 3-50 μm.

6. The method of claim 5 , wherein a size ratio between the third plurality diamond particles and the agglomerate granule is from about 1 to about 100.

7. The method of claim 6 , wherein the first conditions of temperature and pressure suitable for producing an agglomerate granule are less than 250° C.

8. The method of claim 5 , wherein under the second conditions of temperature and pressure, the agglomerate granule breaks inter-granularly along the binder phase into small pieces to fill into interstitial regions among the third plurality of diamond particles.

9. A method of making a superabrasive compact, comprising:
mixing a first plurality of diamond particles with a second plurality of diamond particles;
subjecting the mixture of the plurality of diamond particles to first conditions of temperature and pressure suitable for producing an agglomerate granule;
mixing the agglomerate granule with a third plurality diamond particles;
positioning the resulting mixture proximate to a substrate, wherein the substrate is a pre-sintered cemented carbide substrate; and
subjecting the resulting mixture and the substrate to second conditions of temperature and pressure suitable to produce the superabrasive compact.

10. The method of claim 9 , wherein the step of mixing a first plurality of diamond particles with a second plurality of diamond particles further comprises mixing with non-catalytic binders.

11. The method of claim 9 , wherein the first plurality of diamond particles with a size ranging from about 1 to about 10 μm, wherein the second plurality of diamond particles with a size ranging from about 10 nm to about 5 μm.

12. The method of claim 9 , wherein the third plurality of diamond particles with a size ranging from about 10 μm to about 100 μm.

13. The method of claim 9 , wherein first conditions of temperature and pressure suitable for producing an agglomerate granule are less than 250° C., wherein under second conditions of temperature and pressure, the agglomerate granule breaks inter-granularly along the binder phase into small pieces to fill into interstitial regions among the third plurality of diamond particles.

14. The method of the claim 9 , wherein a size ratio between the third plurality diamond particles and the agglomerate granule is from about 1 to about 100.

Assignees

• Cnpc Usa Corp
• Beijing Huamei Inc
• China Nat Petroleum Corp

Inventors

• Zhang Kai
• Cheng Chris
• Feng Xiao
• Peng Qi
• Yang Xiongwen

Classifications

• B24D11/003 Primary

  without embedded abrasive particles (B24D11/005 takes precedence) · CPC title

• B24D99/005

  Segments of abrasive wheels · CPC title

• B24D18/0009

  using moulds or presses · CPC title

• C09K3/1436 Primary

  Composite particles, e.g. coated particles · CPC title